Đây là tài liệu sửa chữa xe nâng của hãng TCM Nhật Bản. Dùng cho các kiểu xe như FB10,30-7; FB25-7LB; FB25-7V; FB30-7V; FB35-7S. Dưới đây là trích dẫn về mã lỗi của xe cũng như phương pháp kiểm tra:
- 37 -
3. CONTROL SYSTEM
3.2 MAINTENANCE
3.2.1 TROUBLESHOOTING GUIDE
The CPU board of the controller has an LED (green) which shows the content of errors occurring in
the truck, using their corresponding code numbers that are distinguished by different blinking intervals.
Each error code is displayed by a 2-digit decimal number, with both the second and first digits
blinking at an interval of 0.5 seconds while a pause of 1 second OFF is inserted between the second digit
and the first digit. Once an error code is displayed, an OFF period of 4 seconds is inserted before the
same error code is displayed again. Thereafter, this process is repeated.
If multiple errors occur, the code of the last error detected by the controller is only displayed.
Example: Error code: 23 (Traveling neutral interlock detected)
For errors whose error code is not displayed, refer to the following chart:
The same process
is repeated.
Error code number: 23
LED blinks twice LED blinks three times
LED comes on
LED goes out
No.
1
2
3
4
Problem
Contactor won’t close
although key switch can
be turned on.
Truck won’t move
or operate (traveling,
load handling and EPS
systems)
CPU board LED of
controller won’t work.
Truck won’t travel
despite FR switch (F or
R) or accelerator pedal
operation.
Truck comes to stop
during traveling.
Hard steering wheel
Error
Harness disconnected
between power supply
board and CPU board
DSW1 improperly set
Reverse connection of
A and B connectors of
speed sensor.
U, V, or W phase wire
broken (missing)
Power module open
Accelerator pedal or
its signal circuit wire
broken
Battery overvoltage
detected
PS motor short-circuited
Remedy
Proceed with remedy in numerical order of encircled numbers.
Repair or change harness between CN1R (power
supply board) and CN9 (CPU board).
Set all DSW1 (2-bit SW) on CPU board to OFF.
Check A and B connectors for connection.
Check DU, DV, and DW cables for breakage, and
repair if needed.
Check power modules TMDU, TMDV, and TMDW
and repair if needed.
① Check harnesses between CN2-8,9,20 (CPU
board) and traveling accelerator pedal, and repair
or change if needed.
② Repair or change accelerator pedal unit.
① Check battery connectors for contact.
② Check harness between CN4-2 (CPU board) and
P3 terminal, and repair or change if needed.
③ Check harness between CN4-10 (CPU board)
and P13 terminal.
Check PS motor and wiring for short, and change if
needed.
Reset
Restore to
normal.
Restore to
normal.
Restore to
normal.
Restore to
normal.
Restore to
normal.
Restore to
normal.
Restore to
normal.
Remarks
Use caution when
replacing motor.
Protection is provided if
battery connectors cause
improper contact or get
disconnected during
regeneration.
1. BATTERY AND CHARGER
- 7 -
(3) Operation panel
The operation panel is located on the left side of the cabinet and equipped with a charger control
switches, lamps and service power outlet.
(4) VTM unit
The VTM unit is installed inside the right side frame. It sets the charging time for the battery
assembly by the signal from the operation panel.
■ Major features of VTM unit
① Optimal charge according to battery’s state of charge
Conventionally, overcharge might occur when not so an exhausted battery is charged. On this
charger, the microprocessor judges the battery’s state of charge and changes the normal timer setting
within a specified range for optimal charge.
This setting voltage is compensated properly to provide optimal charge even if there are temperature
changes.
② Super equalizing charge
The microprocessor counts the charging time and automatically provides equalizing charge when a
specified time is reached. The time setting for super equalizing charge is preset properly according
to the ambient temperature after temperature compensation. This function saves the trouble of the
operator’s bothering to press the equalizing charge button.
③ In case of power failure while charging
Unless power failure continues longer than 120 hours, battery charging is normally completed.
■ VTM unit
The VTM is mainly composed of its timer function. The microprocessor of the VTM unit determines
and sets an optimal duration of charging after checking the state of the battery.
Fig. 1.7 Operation Panel
3. CONTROL SYSTEM
- 36 -
○ The key switch is turned to ON when the operator is not in the operator’s seat.
■ The interlock system is activated if any of the following conditions occurs.
Operation of the truck
Traction Pump Power
steering
Blinks (Stays on if parking brake lever is pulled.)
Blinks is displayed
An alarm buzzer will sound for
one half second if the parking
brake lever is in released position.
Blinks (Stays on if parking brake lever is
pulled. No buzzer sounds.)
Within
3 seconds
How to release:
The interlock will be released by sitting down again within 6 seconds
after the truck comes to a stop (or within 9 seconds after leaving the
seat).
If more than 6 seconds (after the truck comes to a stop) or 9 seconds
(after leaving the seat) passes, you must sit down and place the shift
lever and the load handling levers into neutral to release the interlock.
3 seconds
passed
○ The operator leaves the operator’s seat when the key switch is in the
ON position.
× × ×
○ ○ ○
× × ×
How to release:
Turn the key switch to OFF, sit down and turn the key switch to ON.
“ ” will be displayed and the “ N ” mark will blink if the
operator performs any operation other than turning the steering wheel
or shifting the lift lever in the lowering phase (when the shift lever is
not in neutral.)
3.1.4 BACK-DOWN ALARM SYSTEM
Alarm
• If the accelerator pedal is released while the truck is going up a hill in forward, the truck might stop
and then back down the slope. In this case, the anti-roll-off regeneration function will be activated to
cause the backup buzzer to sound, even if the shift lever is in the forward position.
How to release the alarm
• Press the accelerator pedal to release the anti-roll-off regeneration function and the buzzer will stop.
(CAUTION)
• Do not place the shift lever in neutral on a slope — the truck might back down the slope rapidly.
Tile: Tài liệu sửa chữa của xe nâng TCM FB10,30-7
Language: English
Size: 10.3 MB
Format: PDF
- 37 -
3. CONTROL SYSTEM
3.2 MAINTENANCE
3.2.1 TROUBLESHOOTING GUIDE
The CPU board of the controller has an LED (green) which shows the content of errors occurring in
the truck, using their corresponding code numbers that are distinguished by different blinking intervals.
Each error code is displayed by a 2-digit decimal number, with both the second and first digits
blinking at an interval of 0.5 seconds while a pause of 1 second OFF is inserted between the second digit
and the first digit. Once an error code is displayed, an OFF period of 4 seconds is inserted before the
same error code is displayed again. Thereafter, this process is repeated.
If multiple errors occur, the code of the last error detected by the controller is only displayed.
Example: Error code: 23 (Traveling neutral interlock detected)
For errors whose error code is not displayed, refer to the following chart:
The same process
is repeated.
Error code number: 23
LED blinks twice LED blinks three times
LED comes on
LED goes out
No.
1
2
3
4
Problem
Contactor won’t close
although key switch can
be turned on.
Truck won’t move
or operate (traveling,
load handling and EPS
systems)
CPU board LED of
controller won’t work.
Truck won’t travel
despite FR switch (F or
R) or accelerator pedal
operation.
Truck comes to stop
during traveling.
Hard steering wheel
Error
Harness disconnected
between power supply
board and CPU board
DSW1 improperly set
Reverse connection of
A and B connectors of
speed sensor.
U, V, or W phase wire
broken (missing)
Power module open
Accelerator pedal or
its signal circuit wire
broken
Battery overvoltage
detected
PS motor short-circuited
Remedy
Proceed with remedy in numerical order of encircled numbers.
Repair or change harness between CN1R (power
supply board) and CN9 (CPU board).
Set all DSW1 (2-bit SW) on CPU board to OFF.
Check A and B connectors for connection.
Check DU, DV, and DW cables for breakage, and
repair if needed.
Check power modules TMDU, TMDV, and TMDW
and repair if needed.
① Check harnesses between CN2-8,9,20 (CPU
board) and traveling accelerator pedal, and repair
or change if needed.
② Repair or change accelerator pedal unit.
① Check battery connectors for contact.
② Check harness between CN4-2 (CPU board) and
P3 terminal, and repair or change if needed.
③ Check harness between CN4-10 (CPU board)
and P13 terminal.
Check PS motor and wiring for short, and change if
needed.
Reset
Restore to
normal.
Restore to
normal.
Restore to
normal.
Restore to
normal.
Restore to
normal.
Restore to
normal.
Restore to
normal.
Remarks
Use caution when
replacing motor.
Protection is provided if
battery connectors cause
improper contact or get
disconnected during
regeneration.
1. BATTERY AND CHARGER
- 7 -
(3) Operation panel
The operation panel is located on the left side of the cabinet and equipped with a charger control
switches, lamps and service power outlet.
(4) VTM unit
The VTM unit is installed inside the right side frame. It sets the charging time for the battery
assembly by the signal from the operation panel.
■ Major features of VTM unit
① Optimal charge according to battery’s state of charge
Conventionally, overcharge might occur when not so an exhausted battery is charged. On this
charger, the microprocessor judges the battery’s state of charge and changes the normal timer setting
within a specified range for optimal charge.
This setting voltage is compensated properly to provide optimal charge even if there are temperature
changes.
② Super equalizing charge
The microprocessor counts the charging time and automatically provides equalizing charge when a
specified time is reached. The time setting for super equalizing charge is preset properly according
to the ambient temperature after temperature compensation. This function saves the trouble of the
operator’s bothering to press the equalizing charge button.
③ In case of power failure while charging
Unless power failure continues longer than 120 hours, battery charging is normally completed.
■ VTM unit
The VTM is mainly composed of its timer function. The microprocessor of the VTM unit determines
and sets an optimal duration of charging after checking the state of the battery.
Fig. 1.7 Operation Panel
3. CONTROL SYSTEM
- 36 -
○ The key switch is turned to ON when the operator is not in the operator’s seat.
■ The interlock system is activated if any of the following conditions occurs.
Operation of the truck
Traction Pump Power
steering
Blinks (Stays on if parking brake lever is pulled.)
Blinks is displayed
An alarm buzzer will sound for
one half second if the parking
brake lever is in released position.
Blinks (Stays on if parking brake lever is
pulled. No buzzer sounds.)
Within
3 seconds
How to release:
The interlock will be released by sitting down again within 6 seconds
after the truck comes to a stop (or within 9 seconds after leaving the
seat).
If more than 6 seconds (after the truck comes to a stop) or 9 seconds
(after leaving the seat) passes, you must sit down and place the shift
lever and the load handling levers into neutral to release the interlock.
3 seconds
passed
○ The operator leaves the operator’s seat when the key switch is in the
ON position.
× × ×
○ ○ ○
× × ×
How to release:
Turn the key switch to OFF, sit down and turn the key switch to ON.
“ ” will be displayed and the “ N ” mark will blink if the
operator performs any operation other than turning the steering wheel
or shifting the lift lever in the lowering phase (when the shift lever is
not in neutral.)
3.1.4 BACK-DOWN ALARM SYSTEM
Alarm
• If the accelerator pedal is released while the truck is going up a hill in forward, the truck might stop
and then back down the slope. In this case, the anti-roll-off regeneration function will be activated to
cause the backup buzzer to sound, even if the shift lever is in the forward position.
How to release the alarm
• Press the accelerator pedal to release the anti-roll-off regeneration function and the buzzer will stop.
(CAUTION)
• Do not place the shift lever in neutral on a slope — the truck might back down the slope rapidly.
Tile: Tài liệu sửa chữa của xe nâng TCM FB10,30-7
Language: English
Size: 10.3 MB
Format: PDF
